Rotary drilling is one of the key techniques in specialist foundation engineering and plays a decisive role in the construction of foundations for high-rise buildings, bridges and other massive structures. This method makes it possible to drive deep, load-bearing piles into the ground in order to safely transfer high loads. Thanks to its versatility, piling can be used in a wide variety of ground conditions and is therefore a preferred technique in modern civil engineering. This article looks at the various aspects of pile installation, its application, the process, challenges and innovative developments. Finally, the processing of pile heads is discussed.
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What does rotary drilling mean?
Rotary drilling describes the process of drilling and inserting piles into the ground to create stable foundations for buildings. Different methods are used, depending on the soil conditions and project requirements. One of the most common methods is the rotary drilling method, in which a rotating drilling tool cuts the ground and transports the drilled material upwards. This technique makes it possible to produce bored piles with variable diameters and depths that can be adapted to the respective structural requirements.
Areas of application for rotary drilling in the construction industry
Rotary drilling is used in various construction projects, in particular for:
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high-rise buildings: Deep piles are indispensable for safely transferring the enormous loads to deeper, load-bearing soil layers.
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Bridge construction: The foundations of bridges must withstand dynamic loads and environmental influences. Stable foundations can be created by producing piles.
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Industrial plants: Machines and plants with high point loads require load-bearing foundations, which can be realized by means of pile production.
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Hydraulic structures: Piles are driven into the ground in ports, quays and offshore structures to ensure permanent stability.
The process of rotary drilling
The rotary drilling process comprises several essential steps:
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Ground investigation: Before work begins, a geotechnical investigation is carried out to analyze the ground conditions and select the appropriate drilling technology.
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Setting up the drilling rig: Depending on the project requirements and ground conditions, the appropriate drilling technology and equipment is selected.
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Drilling process: The drilling tool is driven into the ground with rotating movements and transports the drilling material upwards.
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Use of a drill casing: In unstable ground conditions, a casing is used to prevent the ground from slipping into the borehole.
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Cleaning the borehole: Once the desired depth has been reached, the borehole is cleaned of drill cuttings and sludge.
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Installation of the reinforcement: A reinforcement cage is inserted into the drilled hole to reinforce the pile.
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Concreting: Concreting is carried out using the tremie method or an internal delivery line to ensure perfect concrete quality.
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Curing: The concrete hardens before the pile head is further processed for the connection to the structure.
Advantages of rotary drilling
Rotary drilling offers numerous advantages:
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High load-bearing capacity: Piles safely transfer the structural load to deeper, load-bearing soil layers.
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Flexibility: Various drilling methods enable adaptation to a wide range of geological conditions.
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Precision: Modern drilling techniques ensure exact positioning and execution of the piles.
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Efficiency: Advanced machine technology allows the drilling process to be carried out quickly and economically.
Challenges in rotary drilling
Despite the numerous advantages, there are also challenges:
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Noise and vibration emissions: The drilling process can cause considerable noise pollution and vibrations.
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Wear on drilling tools: Hard rock layers lead to increased wear on drilling equipment and tools.
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Soil instability: In water-bearing or loose soil structures, there may be problems with the stability of the drill wall.
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Environmental requirements: The disposal of drilling waste and the protection of groundwater sources represent additional requirements.
Pile head processing: The final stage of pile production
Once the piles have been installed, the pile heads are machined. This process is crucial to ensure a secure and force-fit connection between the pile and the structure. Protruding concrete is removed and the pile head is brought to the required height.
Traditional methods of pile head processing are often labor-intensive and associated with safety risks. However, modern technologies offer more efficient and safer alternatives.
Pile processing with Brextor®
Brextor® is an innovative system for pile head processing. This technology enables precise, safe and fast removal of the pile head compared to conventional methods.
With this method, not only single piles, but also all types of pile walls (tangent, secant or contiguous) are processed gently by machine. The work is done by one person and one machine. The weather conditions have no influence here.
Brextor® offers the following advantages:
🏗 Increased construction quality
Perfect pile breaking without cracks in the pile body or spalling on the pile outer skin, no bent or torn reinforcements and a height accuracy of +/- 1cm.
💵 Reduced construction costs
The demolition material consists of 80% gravel 0-30mm and can therefore be reused directly on the construction site. In addition, Brextor® requires less working space than conventional mining methods. This means that not only expenses for transportation and disposal incl. fees are saved, but the purchase and supply of replacement material is also eliminated. Furthermore, the preparatory work eliminates the need for a separating diamand cut at the final extraction level and the cleaning effort is massively lower than with conventional extraction methods.
⏱ Shortened processing time
For example, a pile with a diameter of 1 m and a height of 1 m can be processed within 40 minutes. A daily output of up to 16 piles is possible. In addition, Brextor® provides reliable performance and therefore increased planning security.
♻️ Environmentally friendly
With Brextor®, the demolition material (80% gravel 0-30mm) can be reused directly on the construction site. Brextor® also requires less working space. This saves excavation and replacement material. By reusing the demolition material directly on the construction site and saving on excavation and replacement material, transportation can be saved. In addition, landfills are less polluted.
👷 Increased health & safety at work
No heavy physical labor is required for pile processing, which massively reduces the risk of health hazards such as HAVS syndrome. Brextor® also avoids working in danger zones.
Find out more about Brextor® here:
Contact us for more information and find out how you can benefit from this revolutionary pile breaking method.
Call us on +41 41 495 05 20 or send an e-mail to info@brc.swiss. We look forward to working with you and taking your projects to the next level.